Abrasive pad assembly

ABSTRACT

An abrasive pad assembly, for use with a surfacing machine, includes a circular pad member and a diamond abrasive member. The circular pad member includes an exterior surface and the diamond abrasive member is affixed to the exterior surface of the circular pad member. The diamond abrasive member includes an insert and a diamond abrasive material. The insert has a first surface affixed to the exterior surface of the circular pad member. The diamond abrasive material is a polycrystalline diamond substance that is affixed to the second surface of the insert. The polycrystalline diamond material is spaced apart from the exterior surface of the circular pad member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority of U.S. Provisional Application 61/603,676 filed Feb. 27, 2012, the contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention is directed to a nonwoven abrasive pad. More particularly, the present invention is directed to a nonwoven abrasive pad having a diamond abrasive member.

BACKGROUND OF THE INVENTION

It is well known in the art to provide surfacing machines with abrasive pads. The surfacing machines are used for grinding, scrubbing, and polishing floor surfaces including concrete and stone floors.

The abrasive pads are typically formed of a woven or nonwoven material. Nonwoven pads consist of synthetic fibers or natural fibers such as hog hair, coconut fibers, and the like. An abrasive material is typically formed on an outer surface of the pads. The abrasive material includes diamonds which are used in the surfacing operation of the floors. The pads include a rigid backing member which is affixed to the surfacing machine.

A particular disadvantage of the previously known abrasive pads is the rapid deterioration thereof. Specifically, during the surfacing of uneven floors the previously known abrasive pads wear out too frequently. Further, the previously known abrasive pads fail to provide a proper burnish on floors having an uneven surface including a natural stone or floors having a faux stone surfacing texture.

Thus, there exists a need in the art to provide a nonwoven abrasive pad having an abrasive material which allows for extended use and provides a proper surfacing effect on floors having uneven surfaces.

SUMMARY OF THE INVENTION

The present invention provides a nonwoven abrasive pad having an abrasive material which overcomes the above mentioned disadvantages of the previously known abrasive pads, thereby providing increased wear resistance and proper surfacing effects on uneven floors.

In brief, the abrasive pad assembly, for use with a surfacing machine, includes a circular pad member and a diamond abrasive member. The circular pad member includes an exterior surface and the diamond abrasive member is affixed to the exterior surface of the circular pad member. The diamond abrasive member includes an insert and a diamond abrasive material. The insert has a first surface affixed to the exterior surface of the circular pad member. The diamond abrasive material is a polycrystalline diamond substance that is affixed to the second surface of the insert. The polycrystalline diamond material is spaced apart from the exterior surface of the circular pad member.

In one configuration the circular pad member includes a circumferential outer peripheral edge bounding the exterior surface of the circular pad member. The diamond abrasive member is a plurality of diamond abrasive members which are affixed to the exterior surface of the circular pad member. The plurality of diamond abrasive members are provided adjacent the circumferential outer peripheral edge. The plurality of diamond abrasive members are optionally equally spaced, formed having a regular uniform shape, specifically a uniform circular shape.

In an alternative configuration the abrasive pad assembly includes a secondary ring of diamond abrasive members. The second ring of diamond abrasive members is provided between a primary ring of diamond abrasive members adjacent the circumferential outer peripheral edge of the circular pad member and a central mounting hole. The central mounting hole is used to attach the abrasive pad assembly to a surfacing machine.

In an alternative configuration the abrasive pad assembly includes a circular pad member formed of a pair of pad members, and an intermediate member disposed between the pair of circular pad members. The pair of circular pad members and the intermediate member disposed between the pair of circular pad members forms a stack having an interior surface which attaches to a rigid backing member and an exterior surface opposite the internal surface. The exterior surface of the stack having a diamond abrasive member attached thereto.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the present invention will be had upon reference to the following detailed description when read in conjunction with the accompanying drawings wherein like reference characters refer to like parts throughout the several views and in which:

FIG. 1 is a perspective view illustrating a surfacing machine having the inventive abrasive pad assembly;

FIG. 2A is a bottom view of the abrasive pad assembly;

FIG. 2B is a bottom view of an alternative configuration of the abrasive pad assembly;

FIG. 3 is a cross sectional view of FIG. 2A;

FIG. 4A is a cross-sectional view an alternative configuration of the abrasive pad assembly;

FIG. 4B is a cross-sectional view another alternative configuration of the abrasive pad assembly;

FIG. 5 is a cross-sectional view of an alternative configuration of the abrasive pad assembly;

FIG. 6 is a bottom view of an alternative configuration of the abrasive pad assembly; and

FIG. 7 is a bottom view of an alternative configuration of a diamond abrasive member.

DETAILED DESCRIPTION OF THE INVENTION

The present invention has utility as an abrasive pad assembly for a surfacing machine that provides an abrasive pad that provides increased wear resistance and the ability to properly surface a floor having an uneven surface. Providing an abrasive pad having a diamond abrasive member affixed to an exterior surface of a circular pad member spaced apart from the circular pad member provides focused wear on the resilient diamond abrasive member which prevents wear on the circular pad member.

With reference to FIG. 1, a surfacing machine for providing a surfacing on a surface floor is generally illustrated at 10. The surfacing machine includes a motor 12 that actuates the abrasive pad assembly 14 contained within shield 16. The pad assembly 14 includes a pad member 18 which is secured to the shield 16. The pad assembly 14 is operatively attached to the motor 12 which actuates the pad member 18 to perform the floor surfacing operation. Specifically, the motor 12 actuates the pad member 18 in various known manners illustratively including vibration, rotation, and oscillation.

With reference to FIG. 3, the structure of the pad assembly 14 will now be described. The pad assembly 14 includes a pad member 18, a rigid backing member 24, and a plurality of diamond abrasive members 33. The rigid backing plate 24 is affixed to the shield 16 of the surfacing machine 10. The pad 18 is then affixed to the rigid backing plate 24 as known in the art by the hub 22 which extends through a central mounting hole 20 formed in the pad member 18, as best seen in FIG. 1.

The rigid backing plate 24 has a diameter substantially equal to the diameter of the circular pad member 18. Alternatively, the rigid backing plate 24 includes a diameter that is slightly larger than the diameter of the pad member 18 and includes a circumferential lip 26 that bounds a circumferential outer peripheral edge 28 of the pad member 18. The pad member 18 includes an interior surface 30 and an opposite exterior surface 32. The interior surface 30 abuts against the rigid backing plate 24 when mounted in the surfacing machine 10.

The plurality of diamond abrasive members 33 are formed of an insert 34 and a diamond abrasive material 40. The insert 36 includes a first surface 36 and an opposite second surface 38. The first surface 36 is affixed to the exterior surface 32 of the pad member 18. The second surface 38 is spaced apart from the exterior surface 32 of the pad member 18 a distance equal to the thickness of the insert 34.

The diamond abrasive material 40 is bonded to the second surface 38 of the insert 34. The diamond abrasive material 40 includes a polycrystalline diamond material which providing a surfacing operation on a floor surface by the surfacing machine 10. The insert 34 is formed of various materials illustratively including metal, plastics, and other materials. The diamond abrasive material 40 is securely bonded to the second surface 38 of the insert 34 in an operation based upon the substance of the insert 34. The diamond abrasive material 40 is vacuum brazed to metal inserts 34, bonded to plastic resin inserts, or securely affixed to hybrid resin inserts having metallic strips extending therethrough.

In the configuration illustrated in FIG. 3 the diamond abrasive material 40 is spaced apart from the exterior surface 32 of the pad member 18. Specifically, the insert 34 acts as a shield between the diamond abrasive material 40 and the exterior surface 32 of the pad member 18 allowing the friction of the surfacing operation to be focused on the resilient diamond abrasive material 40 which prevents wear on the circular pad member 14. As described below, the inserts 34 are formed having various shapes and sizes along with a spacing array dependent on the application of the abrasive pad assembly 14. In the illustrated embodiments, the diamond abrasive members 33, including the insert 34 and the diamond abrasive material 40, are formed of a generally uniform regular circular shape.

The first surface 36 of the insert 34 is affixed to the exterior surface 32 of the pad member 18 by an adhesive. Specifically, the inserts are affixed to the pad member 18 with a suitable adhesive such as an adhesive containing 40-50% Polyisocyanate Prepolymer based on MDI; 25-30% Polymeric Diphenylmethane Diisocyanate (PMDI); 20-30% 4,4′-Diphenylmethane Diisocyanate (MDI); and 1-5% Diphenylmethane Diisocyanate (MDI) mixed isomers. A suitable adhesive of this type is commonly sold under the trademark Gorilla Glue.

With reference to FIGS. 2A and 2B, the configuration of the diamond abrasive members 33 will now be discussed. As seen in FIG. 2A, the plurality of diamond abrasive members 33 are placed in a primary circular ring 42. Each of the diamond abrasive members 3 of the primary ring are placed adjacent the outer peripheral circumferential edge 28 of the pad member 18. The plurality of diamond abrasive members 33 are slightly spaced apart by approximately ¼ inch. The primary ring of diamond abrasive members 33 are equally spaced and are positioned such that a distance between the diamond abrasive members 33 and the circumferential outer peripheral edge 28 is less than a distance between the diamond abrasive members 33 and the central mounting hole 20.

With reference to FIG. 2B, a secondary ring 44 of diamond abrasive members 33 is provided on exterior surface 32 of the pad member 18. The secondary ring 44 is formed similar to the plurality of diamond abrasive members 33 which form the primary ring 42 positioned adjacent the outer circumferential peripheral edge 28 of the pad member 18. The secondary ring 44 is placed between the primary ring 42 and the central mounting hole 20 of the pad member 18. As seen in FIG. 2B, the plurality of diamond abrasive members 33 forming the secondary ring 44 are formed of similarly shaped generally uniform and regular circular shapes as the plurality of diamond abrasive members 33 which form the primary ring 42.

The pad assembly with the diamond abrasive members 33 in the primary ring 42, as in FIG. 2A, and with a primary ring 42 and secondary ring 44, as in FIG. 2B, provides a superior ability to surface floors having an uneven surface. The placement of the diamond abrasive members 33 at the circumferential outer peripheral edge 28 combined with the nonwoven pad member 18 provides flexibility that allows the diamond abrasive material 40 to surface the uneven floors while permitting sufficient pressure to be applied to properly surface the floors. In addition, the placement of the diamond abrasive material 40 apart from the exterior surface 32 of the pad member 18 focuses the wear on the diamond abrasive members 33 while preventing premature wear on the pad members 18.

It is appreciated, of course, that the diamond abrasive members 33, including the inserts 34 and the diamond abrasive material 40, are not limited to such a regular and uniform geometric shape. Specifically, the diamond abrasive members 33 can be formed in various geometric shapes illustratively including rectangles, triangles, polygons, and arc segments. Moreover, the abrasive members 33 can be formed of various irregular and nonuniform shapes such as trailing spirals.

With reference to FIGS. 4A and 4B, alternative configurations of assembly will now be discussed. Although not illustrated, the pad assemblies 114 and 214 of FIGS. 4A and 4B include the rigid backing plate 24. As shown in FIG. 4A, the abrasive pad assembly 114 includes a pad member 118 having recessed pockets 146 formed in the exterior surface 132. The recessed pockets 146 are provided with a depth that is generally equal to or slightly less than the thickness of the inserts 134. Each of the inserts 134 is provided in the recesses 146 such that the first surface 136 abuts the bottom of the recessed pockets 146 such that the opposite second surface 138 of the inserts 134 extends beyond the exterior surface 132 of the pad member 118. With such configuration the diamond abrasive material 140 are provided spaced apart from the exterior surface 132 of the pad member 118 while reducing the overall thickness of the pad assembly 114.

An alternative configuration of the abrasive pad assembly 214 is illustrated in FIG. 4B. The abrasive pad assembly 214 includes an diamond abrasive member 233, including insert 234 and diamond abrasive material 240, having a generally circular shape with a diameter slightly less than the diameter of the pad member 218. In addition, an insert mounting hole 245 having a diameter generally equal to the mounting hole 220 of the pad member 218 is formed. The insert mounting hole 245 is positioned on the insert 234 such that upon attachment of the insert 34 to the exterior surface 232 of the pad member 218 the insert mounting hole 245 aligns with the mounting hole 220 to allow for the mounting of the abrasive pad assembly 214 to the surfacing machine 10.

With reference to FIG. 5, an alternative configuration of the abrasive pad assembly 314 is illustrated. The abrasive pad assembly 314 includes stacked pad 350 formed of a pair of corresponding pad members 318A and 318B, and an intermediate member 348. The intermediate member 348 is disposed between the pair of pad members 318A and 318B. The stacked pad 350 is formed by positioning one of the pair of pad members 318A and 318B on either side of the intermediate member 348. The pair of pad members 318A and 318B are formed of a nonwoven material. The stack pad 350 is securely fixed through various bonding operations including adhesives, heat welding, and ultrasonic welding.

The intermediate member 348 acts as a heat shield to keep heat generating during the surfacing operation from dissipating and offers additional rigid support of the abrasive pad assembly 314. The stack pad 350 includes an interior surface 330 which abuts the rigid backing member 324 and an opposite exterior surface 332 to which the first surface 336 of the inserts 334 is affixed. A suitable stack pad 350 is manufactured by ETC of Henderson and is sold under the trademark Heat By Gorilla®.

The intermediate member 348 is formed of a rigid or semi rigid polymeric, plastic, resin or rubber material that has a rigidity that is greater than the rigidity of the pair of pad members 318A and 318B. The intermediate member 348 is formed having a thickness that is less than a thickness of each of the pair of pad members 318A and 318B. The upper and lower pair of pad members 318A and 318B allow for compression while the stack pad 350 travels over uneven floor surfaces while still performing surfacing operations. During high speed revolutions the intermediate member 348 provides the structural rigidity to the pair of pad members 318A and 318B having a sufficient shear force to maintain the weight of the diamond abrasive member 533. The combination of the compressible pair of pad members 318A and 318B with the rigid structure of the intermediate member 348 allows the stack pad 350 to surface floors having uneven surfaces while preventing the premature wear of the pads.

The intermediate member 348 provides sufficient rigidity to the stack pad 350 allowing for the stack pad 350 to have diameters in the range of 7 inches to 27 inches while still supporting the weight of the inserts 333.

With reference to FIG. 6, an alternative configuration of the abrasive pad assembly is illustrated at 414. The abrasive pad assembly 414 is formed of a pair of pad members and an intermediate member having a generally rectangular shape. The abrasive pad assembly 414 is provided with a plurality of diamond abrasive members 433 equally spaced across the entire surface of the abrasive pad assembly 414. The abrasive pad 414 having the rectangular shape is primarily used with surfacing machines 10 which operate by vibrating or oscillating the abrasive pad.

FIG. 7 illustrates an isolated view of the insert 533 having a unique configuration on the second surface 538. The second surface 538 includes a central nub 552 surrounded by a plurality of radially extending grooves 554 and a plurality of concentric circular grooves 556. The configuration allows for debris and dust caused during the surfacing operation to be guided towards the exterior of the diamond abrasive member 533.

The pad members are formed of various materials including synthetic and natural fibers fused in a nonwoven manner. Specifically, the nonwoven pad members are formed of natural fibers such as hog hair, coconut fibers, and the like. Further still, the pad members are optionally formed of synthetic and natural materials having various rigidity varying from rigid plastic or rubber pad members to flexible/pliable nonwoven pad members formed of natural fibers.

Moreover, although FIG. 1 illustrates a surfacing machine 10 as a tri-headed riding surfacing machine, the inventive abrasive pad assembly is not limited to use with such machine. Specifically, the abrasive pad assembly is operably attached to a surfacing machine such as cylindrical surfacing machines, rotating circular surfacing machines, planetary surfacing machines, and vibrating/oscillating surfacing machines.

The present invention is not restricted to the illustrative examples and embodiments described herein. The embodiments are not intended as limitations on the scope of the invention. Having described the invention, however, many modifications thereto will become apparent to those skilled in the art to which it pertains without deviation from the spirit of the invention as defined by the scope of the attached claims. 

It is claimed:
 1. An abrasive pad assembly for use with a surfacing machine to surface a floor, said abrasive pad assembly comprising: a pad member having an exterior surface, said pad member formed of a nonwoven material; and a diamond abrasive member having an insert and a diamond abrasive material, said insert having a first surface and an opposite second surface, said first surface being affixed to said exterior surface of said pad member, and said diamond abrasive material is affixed to said second surface of said insert.
 2. The abrasive pad assembly of claim 1, wherein said diamond abrasive material is a polycrystalline diamond substance.
 3. The abrasive pad assembly of claim 2, wherein said polycrystalline diamond substance is spaced apart from said exterior surface of said pad member by a thickness of said insert.
 4. The abrasive pad assembly of claim 3, wherein said diamond abrasive member is a plurality of diamond abrasive members, said plurality of diamond abrasive member are affixed to said exterior surface of said circular pad member.
 5. The abrasive pad assembly of claim 4, wherein said pad member is formed of an intermediate member positioned between a pair of pad members formed of a nonwoven material, said intermediate member having a rigidity that is greater than a rigidity of said pair of pad members, each of said pair of pad members having an inner surface affixed to said intermediate member, and one of said pair of pad members having an exterior surface opposite said inner surface, said exterior surface having said plurality of diamond abrasive members affixed thereto.
 6. The abrasive pad assembly of claim 5, wherein said pad member is formed having a generally circular shape, said pad member includes a circumferential outer peripheral edge bounding said exterior surface, and wherein said plurality of diamond abrasive members are provided adjacent said circumferential outer peripheral edge.
 7. The abrasive pad assembly of claim 6, wherein said plurality of diamond abrasive members are formed having a regular uniform shape, and wherein said plurality of diamond abrasive members are equally spaced adjacent said circumferential outer peripheral edge.
 8. The abrasive pad assembly of claim 7, wherein each of said plurality of diamond abrasive members have a uniform circular shape.
 9. The abrasive pad assembly of claim 6, wherein a secondary ring of equally spaced diamond abrasive members is positioned between said plurality of diamond abrasive members adjacent said circumferential outer peripheral edge and a center of said pad member.
 10. A surfacing machine for surfacing a floor comprising: a motor; a pad member having an exterior surface, said motor operates to actuate said pad member to perform the surfacing operation; a diamond abrasive member having an insert and a diamond abrasive material, said insert having a first surface and an opposite second surface, said first surface being affixed to said exterior surface of said pad member, and said diamond abrasive material is affixed to said second surface of said insert.
 11. The surfacing machine of claim 10, wherein said diamond abrasive material is a polycrystalline diamond substance.
 12. The surfacing machine of claim 11, wherein said polycrystalline diamond substance is spaced apart from said exterior surface of said pad member by a thickness of said insert.
 13. The surfacing machine of claim 12, wherein said diamond abrasive member is a plurality of diamond abrasive members, said plurality of diamond abrasive member are affixed to said exterior surface of said circular pad member.
 14. The surfacing machine of claim 13, wherein said pad member is formed of an intermediate member positioned between a pair of pad members formed of a nonwoven material, said intermediate member having a rigidity that is greater than a rigidity of said pair of pad members, each of said pair of pad members having an inner surface affixed to said intermediate member, and one of said pair of pad members having an exterior surface opposite said inner surface, said exterior surface having said plurality of diamond abrasive members affixed thereto.
 15. The surfacing machine of claim 14, wherein said pad member is formed having a generally circular shape, said pad member includes a circumferential outer peripheral edge bounding said exterior surface, and wherein said plurality of diamond abrasive members are provided adjacent said circumferential outer peripheral edge.
 16. The surfacing machine of claim 15, wherein said plurality of diamond abrasive members are formed having a regular uniform shape, and wherein said plurality of diamond abrasive members are equally spaced adjacent said circumferential outer peripheral edge.
 17. The surfacing machine of claim 16, wherein each of said plurality of diamond abrasive members have a uniform circular shape.
 18. The abrasive pad assembly of claim 6, wherein a secondary ring of equally spaced diamond abrasive members is positioned between said plurality of diamond abrasive members adjacent said circumferential outer peripheral edge and a center of said pad member.
 19. An abrasive pad assembly for use with a surfacing machine to surface a floor, said abrasive pad assembly comprising: a pair of pad members each having an inner surface and an opposite exterior surface, said pair of pad members formed of a nonwoven material; an intermediate member positioned between said inner surfaces of said pair of pad members, said intermediate member having a rigidity that is greater than a rigidity of said pair of pad members; and a diamond abrasive member having an insert and a diamond abrasive material, said insert having a first surface and an opposite second surface, said first surface being affixed to one of said exterior surfaces of said pair of pad members, and said diamond abrasive material is affixed to said second surface of said insert.
 20. The abrasive pad assembly of claim 19, wherein each of said pair of pad members and said intermediate member are formed having a generally circular shape, and wherein said diamond abrasive member is a plurality of diamond abrasive members, said plurality of diamond abrasive member are affixed to said exterior surface of one of said pair of pad members, said diamond abrasive members are positioned equally spaced and adjacent a circumferential outer peripheral edge. 